Method and apparatus for distributing mold material in a mold for packaging microelectronic devices

ABSTRACT

A method and apparatus for distributing a mold material in a mold for packaging microelectronic devices. In one embodiment, the microelectronic devices are placed on a substrate and the substrate is at least partially enclosed by the device region of a mold cavity. A mold material is passed along a flow axis through at least one entrance port into an intermediate region of the mold. The mold material is then passed from the intermediate region into the device region through a single opening spaced apart from and positioned between the entrance port and the microelectronic device. The single opening has a flow area transverse to the flow axis smaller than a flow area immediately upstream of the single opening to restrict the flow through the single opening. The mold material can accordingly form a uniform leading edge as it exits the opening and before it impinges on the microelectronic device.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of provisional U.S. Application No. 60/240,927, filed May 8, 2000, (formerly non-provisional application Ser. No. 09/566,776) entitled “METHOD AND APPARATUS FOR DISTRIBUTING MOLD MATERIAL IN A MOLD FOR PACKAGING MICROELECTRONIC DEVICES” which is hereby incorporated by reference.

TECHNICAL FIELD

[0002] This invention relates to methods and apparatuses for distributing mold materials in a mold for packaging microelectronic devices.

BACKGROUND OF THE INVENTION

[0003] Packaged microelectronic assemblies, such as memory chips and microprocessor chips, typically include a microelectronic substrate die encased in a protective plastic covering. The die includes functional devices, such as memory cells, processor circuits, and/or interconnecting circuitry. The die also typically includes bond pads electrically coupled to the functional devices. The bond pads are coupled to pins, solder ball pads, or other types of terminals that extend outside the protective covering for connecting to buses, circuits and/or microelectronic assemblies.

[0004] In one conventional arrangement, illustrated in FIGS. 1A and 1B, several dies 40 are positioned on an upper surface of a substrate 30, such as printed circuit board (PCB). Each die 40 includes conductive leads 41 that are electrically coupled through the substrate 30 to solder ball pads on the opposite surface of the substrate 30. A mold 60 (shown in a side cross-sectional view in Figure 1B) is positioned over the substrate 30 with a cavity 67 aligned with the dies 40. The mold 60 is lowered onto the substrate 30 until an engaging surface 69 contacts the upper surface of the substrate 30 and the dies 40 fit within the cavity 67. The cavity 67 is in fluid communication with a plurality of entrance ports 63. Each entrance port 63 has an elongated, narrow gate region 62 aligned with a corresponding gold-plated gate pad 31 on the substrate 30 when the mold 60 is placed against the upper surface of the substrate 30.

[0005] In operation, the entrance ports 63 are coupled to a source (not shown) of softened or liquid mold compound 50. The mold compound 50 is injected through the entrance ports 63 to encapsulate the dies 40, forming a package 20 with gate portions 51 extending outwardly over the gate pads 31. The mold compound 50 is allowed to harden and the package 20 is ejected from the mold 60 by driving ejection pins (not shown) against the package 20 at ejection pin locations 52. The package 20 is then broken off from the gate portions 51 along a break line 59 and is singulated to separate each packaged die 40 (and the portion of the substrate 30 to which each die 40 is attached) from the neighboring packaged dies 40. The dies 50 are preferably positioned close together and close to the edges of the package 20 to reduce the size of the package 20 and the amount of residual or waste mold compound 50 remaining after the packaged dies 40 have been singulated.

SUMMARY OF THE INVENTION

[0006] The present invention is directed toward methods and apparatuses for distributing a mold material in a mold for packaging microelectronic devices. A method in accordance with one aspect of the invention includes at least partially enclosing in a mold a microelectronic device attached to a substrate, with the microelectronic device in a device region of the mold. The method further includes passing a mold material along a flow axis through at least one entrance port into and through an intermediate region of the mold. The method still further includes encapsulating the microelectronic device by passing the mold material from the intermediate region into the device region through a single opening spaced apart from and positioned between the entrance port and the microelectronic device. The single opening has a flow area transverse to the flow axis smaller than a flow area immediately upstream of the single opening in the intermediate region of the mold.

[0007] In a further aspect of the invention, the method can include hardening the mold material, separating a first portion of the mold material adjacent to the at least one entrance port from a second portion of the mold material adjacent the intermediate region of the mold to form cracks in the second portion of the mold material, with none of the cracks intersecting the microelectronic device. The cracks define a cracked portion of the mold material and the method can further include separating the cracked portion of the mold material from the microelectronic device.

[0008] The invention is also directed toward a microelectronic device package. In one aspect of the invention, the package includes a substrate, at least one microelectronic device attached to the substrate, and a hardened mold material at least partially enclosing the microelectronic device. The mold material has a device portion immediately adjacent to the microelectronic device, a gate portion spaced apart from the device portion, and the intermediate portion between the gate portion and the device portion. The mold material further includes an indentation at an intersection of the device portion and the intermediate portion. A first cross-sectional area of the mold material at the intersection is less than a second cross-sectional area immediately adjacent to the intersection in the device portion, and also less than a third cross-sectional area immediately adjacent to the intersection in the intermediate portion.

[0009] The invention is also directed toward a mold for packaging a plurality of microelectronic devices. In one aspect of the invention, the mold includes a mold body having an external surface, an internal surface defining a mold cavity, and an engaging surface configured to engage the substrate. The mold cavity includes a device region configured to extend at least partially around the microelectronic devices, at least one entrance port in fluid communication with the device region, an intermediate region between the entrance port and the device region, and a flow restrictor between the intermediate region and the device region. The cross-sectional areas of the mold cavity immediately upstream and downstream of the flow restrictor are larger than a cross-sectional area of the mold cavity at the flow restrictor.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1A is a top plan view of a device package having a substrate with a plurality of encapsulated dies in accordance with the prior art.

[0011]Figure 1B is a cross-sectional side elevation view of a mold for encapsulating the dies of FIG. 1A in accordance with the prior art.

[0012]FIG. 2A is a cross-sectional elevation view of a mold positioned above a substrate after encapsulating microelectronic devices on the substrate in accordance with an embodiment of the invention.

[0013]FIG. 2B is a bottom plan view of a portion of the mold shown in FIG. 2A.

[0014]FIG. 3 is a partially schematic, top plan view of the substrate and encapsulated microelectronic devices shown in FIG. 2.

[0015]FIG. 4A is a top plan view of a substrate having encapsulated microelectronic devices in accordance with other embodiments of the invention.

[0016]FIG. 4B is a bottom plan view of a mold for encapsulating the microelectronic devices shown in FIG. 4A.

DETAILED DESCRIPTION

[0017] The conventional method described above with reference to FIGS. 1A and 1B can suffer from several drawbacks. For example, when the package 20 is broken away from the hardened gate portions 51, crevices or cracks can develop in the mold compound 50 adjacent to the dies 40. These cracks can propagate to the dies 40 and can allow moisture or other contaminants to contact and adversely affect the performance of the dies 40. Another drawback is that the flow of the mold compound 50 into the cavity 67 may not be uniform, which can distort or deform the wire leads 41 extending away from each die 40, and/or can leave air gaps between the dies 40 and the walls of the cavity 67. When the encapsulated dies 40 are separated from each other, moisture and other contaminants can seep through the air gaps and contact the dies 40.

[0018] The present disclosure describes microelectronic device packages and methods for manufacturing such packages that can address the foregoing drawbacks. Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 2A-4B to provide a thorough understanding of these embodiments. One skilled in the art, however, will understand that the present invention may have additional embodiments, or that the invention may be practiced without several of the details described below.

[0019]FIG. 2A is a cross-sectional side view of a mold 160 positioned above a substrate 130 after encapsulating microelectronic devices 140 on the substrate 130 to form a device package 120 in accordance with an embodiment of the invention. FIG. 2B is a bottom plan view of a portion of the mold 160 shown in FIG. 2A. Referring to FIGS. 2A and 2B, the substrate 130 can include a generally flat, thin support member, such as a PCB having an upper surface 133, a lower surface 134, and conductive layers and/or vias (not shown) extending between the upper and lower surfaces 133 and 134. The microelectronic devices 140 are positioned on the upper surface 133 and are coupled to one end of the vias by conductive leads 141. The opposite ends of the vias are coupled to ball bond pads 132 on the lower surface 134 of the substrate 130. The microelectronic devices 140 and part of the substrate upper surface 133 are encapsulated with a mold material 150 (such as an epoxy resin) to protect the microelectronic devices 140 from moisture, oxidizers, and other environmental contaminants.

[0020] The mold material 150 is formed around the microelectronic devices 140 by positioning an engaging surface 169 of the mold 160 against the upper surface 133 of the substrate 130 and injecting the mold material 150 into the mold 160, as indicated by arrow A. Accordingly, the mold 160 includes a mold cavity 167 having a device region 161 that partially encloses the microelectronic devices 140. In one embodiment, the device region 161 is in fluid communication with a plurality of entrance ports 163 that are coupled to a source (not shown) of the mold material 150. Alternatively, the device region 161 can be supplied by a single entrance port 163. In either embodiment, the mold material 150 flows through the entrance port(s) 163 and into the device region 161 where it hardens to encapsulate the devices 140. As the mold material 150 flows into the mold 160, it forces air out from the mold 160 through air vents (not shown).

[0021] In one embodiment, the mold cavity 167 includes a plurality of gate regions 162 just downstream of the entrance ports 163. Each gate region 162 has a shorter vertical extent (as seen in FIG. 2A) than other portions of the cavity 167 so that gate portions 151 of the mold material 150 (i.e., the portions of the mold material 150 that harden in the gate regions) are relatively small and fragile. Accordingly, the device package 120 can be easily separated from the gate portions 151, as described below with reference to FIG. 3. In a further aspect of this embodiment, each gate region 162 of the mold 160 is aligned with a gate pad 131 on the substrate 130. Each gate pad 131 can be gold-plated to allow the gate portions 151 of the mold material 150 to more easily separate from the substrate 130. Accordingly, the device package 120 can be more easily separated from the gate portions 151.

[0022] In one embodiment, the cavity 167 further includes an intermediate region 164 between the gate regions 162 and the device region 161. In one aspect of this embodiment, the flow area of the intermediate region 164 (i.e., the cross-sectional area of the intermediate region 164, taken normal to the flow direction of the mold material through the cavity, indicated by arrow A) is greater than the combined flow areas of the gate regions 162. Accordingly, separate flows of mold material 150 entering the intermediate region 164 from adjacent gate regions 162 will tend to coalesce in the intermediate region 164 before advancing to the device region 161.

[0023] In another aspect of this embodiment, the mold 160 includes a flow restriction 165 that defines an opening 166 between the intermediate region 164 and the device region 161. The restriction 165 forms an indentation 158 in the mold material 150 and can further improve the uniformity of the flow of mold material 150 into the device region 161 of the cavity 167. For example, in one embodiment, a depth D of the restriction 165 is from about 0.05 mm to about 0.2 mm (relative to an upper surface of the intermediate region 164) and in other embodiments, the depth D can have other values and/or arrangements. For example, the restriction 165 can extend transverse to the plane of FIG. 2A. In any of these embodiments, the restriction 165 and the opening 166 can control the flow of the mold material 150 in a manner described in greater detail below with reference to FIG. 3.

[0024] In one embodiment, the opening 166 has a flow area transverse to the plane of the substrate 130 that is less than a flow area immediately downstream of the opening, in the device region 161. The flow area of the opening 166 is also less than a flow area immediately upstream of the opening 166 in the intermediate region 164. In a further aspect of this embodiment, the opening 166 is spaced apart from a forward edge 144 of the nearest microelectronic device 140 by distance 155 a of from about 4 mm to about 6 mm. The distance 155 a can be about 5.6 mm for an embodiment of the configuration shown in FIG. 2A.

[0025] In one aspect of an embodiment shown in FIG. 2A, a height H₁ of the intermediate region 164 is greater than a height H₂ of the gate regions 162. In another aspect of this embodiment, the height H₁ of the intermediate region 164 is less than or equal to a height H₃ of the device region 161. For example, in one embodiment, H₁ is about 0.1 mm and H₃ is about 0.2 mm. Accordingly, an intermediate portion 153 of the hardened mold material 150 in the intermediate region 164 will not project above a device portion 156 of hardened mold material 150 in the device region 161. As a result, the package 120 can lie flat when removed from the mold 160, inverted, and placed on a flat surface. Keeping the device package 120 in a flat orientation can be important in subsequent processing steps, such as attaching solder balls to the ball bond pads 132.

[0026]FIG. 3 is a top plan view of the substrate 130, the mold material 150 and the microelectronic devices 140 shown in FIG. 2A. In one embodiment, the microelectronic devices 140 are arranged in a 2×5 array 143 (outlined in dashed lines in FIG. 3). In other embodiments, the package 120 can have more or fewer microelectronic devices 140 positioned in other arrangements, as will be described in greater detail below with reference to FIG. 4. In still further embodiments, the microelectronic devices 140 can be stacked on each other, and the stacked devices can be arranged in the array 143. In any of these embodiments, the device portion 156 of the mold material 150 surrounds the microelectronic devices 140 and corresponds to the shape and size to the device region 161 of the mold cavity 167 (FIGS. 2A, 2B). The intermediate portion 153 of the mold material 150 (which corresponds in shape and size to the intermediate region 164 of the mold cavity 167) extends between the device portion 156 and four gate portions 151 (which correspond in shape and size to the gate regions 162).

[0027] During the injection of the mold material 150 into the cavity 167, the mold material 150 has a leading edge 157 that advances over the substrate 130 and the microelectronic devices 140. For purposes of illustration, the leading edge 157 is shown in FIG. 3 at four sequential positions, identified by letters Q, R, S, and T. Referring now to FIGS. 2A, 2B and 3, when the mold material 150 first enters the intermediate region 164 (position Q), it forms separate leading edge portions 157 a at the junctions between each gate region 162 and the intermediate region 164. As the leading edge portions 157 a progress through the intermediate region 164, they merge to form a single leading edge 157 (position R).

[0028] In one aspect of an embodiment shown in FIGS. 2A, 2B and 3, the mold material 150 completely fills the intermediate region 164 before passing through the opening 166 leading to the device region 161. Alternatively, the mold material 150 begins to pass through the opening 166 before the entire intermediate region 164 fills, but before the mold material 150 first contacts any of the microelectronic devices 140. In either of these embodiments, at least a portion of the leading edge 157 flattens as it passes through the opening 166 (position S). The leading edge 157 maintains a generally straight, flattened profile as it approaches and engages the nearest microelectronic device 140 (position T), with the leading edge 157 parallel to or approximately parallel to the forward-facing edge 144 of at least one of the devices 140 and/or the device array 143. In one aspect of this embodiment, the leading edge 157 is at least approximately parallel to the entire length of the forward-facing edge 144 of one or more of the microelectronic devices 140. Accordingly, the leading edge 157 can be parallel to a substantial portion of the edge of the device array 143.

[0029] In one aspect of an embodiment shown in FIGS. 2A, 2B and 3, sidewalls of the intermediate region 164 of the mold 160 are canted outwardly to form canted sidewalls 174 of the mold material 150 (FIG. 3). In one embodiment, the sidewalls 174 are canted by an included angle C of about 60°±20°, and in other embodiments, the included angle C can have other values, so long as the intermediate region sidewalls do not inhibit the flow of the mold material 150 into the device region 161.

[0030] After the mold material 150 encapsulates the microelectronic devices 150, the mold material 150 is cured or otherwise allowed to harden. The encapsulated microelectronic devices 140 and the substrate 130 are removed as a unit from the mold 160 and are separated from the gate portions 151 along a separation line 159 to form the device package 120. The intermediate portion 153 is then removed from the package is 120. In one embodiment, the microelectronic devices can remain together in the package 120; alternatively, the package 120 can be singulated to separate each encapsulated device 140 for individual coupling to other devices and/or circuits.

[0031] In one aspect of an embodiment described above with reference to FIGS. 2A, 2B and 3, a ratio of the width W₁ of the intermediate portion 153 (transverse to the flow direction A) to a length of L₁ of the intermediate portion 153 (aligned with the flow direction A) can be from about 10 to about 15. In other embodiments, this ratio can have other values that result in relatively uniform mold material leading edges 157. In another aspect of these embodiments, a ratio of the width W₁ of intermediate portion 153 to a width W₂ of the device portion 156 can be from about 0.3 to about 1.0. A ratio of the length L₁ of the intermediate portion 153 to a length L₂ of the device portion 156 can be from about 0.02 to about 0.10. A ratio of a volume of the intermediate portion 153 to a volume of the device portion 156 can be from about 0.02 to about 0.07.

[0032] One feature of an embodiment of the apparatus and method described above with reference to FIGS. 2A, 2B and 3 is that the intermediate region 164 is sized to allow the individual leading edge portions 157 a to coalesce and form a leading edge 157 that is parallel to or approximately parallel to the array 143 over the entire forward edge 144 of at least one of the microelectronic devices 140. Accordingly, the leading edge 157 is transverse to the primary axial flow direction A of the mold material 150 as the mold material 150 enters the cavity 167. One advantage of this feature is that the mold cavity 167 can more uniformly fill with mold material 150, reducing the likelihood for forming air pockets in the hardened mold material 150. As such, it is expected that several embodiments of the device package 120 will not be impaired by moisture or other contaminants.

[0033] Another advantage is that the uniform leading edge 157 is less likely to damage the leads 141. For example, the leading edge 157 will be approximately perpendicular to most of the leads 141 because the leading edge is generally straight and transverse to the flow direction A. This is unlike some conventional leading edges that are highly bowed and can accordingly strike the leads 141 with a substantial transverse velocity component. This transverse velocity can break or bend the leads 141. The relatively straight leading edge 157 may also be less likely than conventional mold material leading edges to bend or break the leads 141 proximate to an aft edge 145 of the devices 140 and/or the device array 143. For example, with conventional highly bowed leading edges, some of the mold material 150 may pass through the entire device array 143 to a rear edge 168 of the cavity 167 well ahead of the rest of the mold material 150. This advance portion of the mold material 150 can reflect from the rear edge 168 and generate lateral waves that strike the leads 141 at the aft edges 145 of the devices 140 with a substantial transverse velocity causing the leads 141 to bend or break.

[0034] Still another feature of the generally straight leading edge 157 is that it can provide for a more robust process than a conventional bowed leading edge. For example, in some conventional arrangements, the positions of the microelectronic devices relative to the leading edge are carefully controlled to reduce the tendency for bending and/or breaking the leads 141, and to reduce the tendency for forming air pockets in the hardened mold material. Conversely, when the generally straight leading edge 157 is introduced into the mold cavity 167, it can withstand perturbations caused by the microelectronic devices 140 without altering its shape so substantially that it damages the leads 141 or increases the number of air pockets or cavities in the mold material 150.

[0035] Accordingly, the positions of the microelectronic devices and other factors associated with the encapsulation process may need not to be as manipulated to accommodate the molding process.

[0036] Still another feature of an embodiment of the apparatus and method described above with reference to FIGS. 2A, 2B and 3 is that a distance 155 b between the separation line 159 and the nearest microelectronic device 140 is larger than it is in conventional arrangements. The presence of the intermediate portion 153 of the mold material 150 increases this distance. Accordingly, the position of the device array 143 relative to the outer edges of the mold compound 150 is asymmetric, with the distance 155 b being greater than a distance 155 c between the device array 143 and the opposite edge of the mold compound 150. An advantage of this feature is that when cracks 170 form in the mold material 150 as the package 120 is separated from the gate portions 151, the cracks 170 are less likely to extend all the way to the devices 140. Accordingly, the intermediate portion 153 of the mold material 150 can reduce the likelihood for contaminants to pass through the cracks 170 to the devices 140.

[0037]FIG. 4A is a top plan view of a microelectronic device package 220 having an array 243 of microelectronic devices 240 arranged on a substrate 130 and encapsulated with a mold material 250 in accordance with another embodiment of the invention. FIG. 4B is a bottom plan view of a mold 260 having a cavity 267 with a device region 261, an intermediate region 264 a, and a plurality of gate regions 262 and entrance ports 263 for encapsulating the microelectronic devices 240 and forming the package 220 shown in FIG. 4A. Referring to FIGS. 4A and 4B, in one aspect of this embodiment, the microelectronic devices 240 can arranged in a 3×5 array, and in other embodiments, the microelectronic devices 240 can be arranged in arrays having other dimensions.

[0038] In either embodiment, the mold material 250 includes a device portion 256 that immediately surrounds the array 243, a plurality of gate portions 251, and an intermediate portion 253 a between the gate portions 251 and the device portion 256. The relative shapes and sizes of each portion of the mold material 250 are determined by the device region 261, the gate region 262 and the intermediate region 264 a, respectively, of the mold 260 in a manner generally similar to that described above with reference to FIGS. 2A, 2B and 3.

[0039] In one aspect of an embodiment shown in FIGS. 4A-4B, the intermediate portion 253 a extends diagonally to opposite side edges 221 of the package 220. Alternatively, the package 220 can include an intermediate portion 253 b (shown in dashed lines) having a rectangular shape that extends to the side edges 221. The mold 260 can include a corresponding rectangular-shaped intermediate region 264 b. In either embodiment, the intermediate portions 253 a and 253 b are slightly larger and have a greater lateral extent than the intermediate portion 153 described above with reference to FIGS. 2 and 3.

[0040] One feature of the arrangement shown in FIGS. 4A-4B is that the wider intermediate regions 264 a and 264 b can accommodate a wider opening 266 between the intermediate region and the device region 261 of the mold 260 used to form the package 220. Accordingly, the leading edge of the mold material 250 passing through the opening 266 can be more uniform. Conversely, an advantage of the arrangement described above with reference to FIGS. 2A-2B and 3 is that the package 120 uses less mold material than the package 220 because the intermediate portion 153 is smaller in the lateral direction than the intermediate portions 253 a and 253 b.

[0041] In other embodiments, the package 220 (and, correspondingly, the mold 260 used to form the package 220) can have other shapes. For example, the package 220 can have a single gate portion 251 (rather than the four gate portions 251 shown in FIG. 4A), so long as the intermediate portion 253 a or 253 b (and the corresponding intermediate region 264 a or 264 b of the mold 260) has a great enough extent in the axial direction A to allow the mold material 250 to form a generally straight leading edge.

[0042] Alternatively, the package 220 can have more than four gate portions 251. In still another alternate embodiment, the gate portions 251 (and, correspondingly, the entrance ports 263 in the mold 260) can introduce the mold material 250 laterally from the sides of the intermediate portion 253 a or 253 b , rather than axially as shown in FIGS. 4A-4B.

[0043] From the foregoing, it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. For example, the substrate 130 can include terminals other than ball bond pads, such as pins. The microelectronic devices and packages can have other sizes, shapes and arrangements, where the mold includes an intermediate portion between the entrance ports and the microelectronic devices and/or a flow restriction upstream of the microelectronic devices. Accordingly, the invention is not limited except as by the appended claims. 

1. A method for packaging at least one microelectronic device attached to a substrate, comprising: at least partially enclosing the microelectronic device and the substrate in a mold with the microelectronic device in a device region of the mold; passing a mold material along a flow axis through at least one entrance port into and through an intermediate region of the mold; and encapsulating the microelectronic device by passing the mold material from the intermediate region into the device region through a single opening spaced apart from and positioned between the entrance port and the microelectronic device, the single opening having a flow area transverse to the flow axis smaller than a flow area immediately upstream of the single opening in the intermediate region.
 2. The method of claim 1, further comprising: hardening the mold material; separating a first portion of the mold material adjacent to the at least one entrance port from a second portion of the mold material adjacent the intermediate region of the mold to form cracks in the second portion of the mold material with none of the cracks intersecting the microelectronic device, the cracks defining a cracked portion of the mold material; and separating the cracked portion of the mold material from the microelectronic device.
 3. The method of claim 1 wherein the substrate defines a substrate plane, further comprising restricting the passage of the mold material through the single opening in a direction transverse to the substrate plane.
 4. The method of claim 1, further comprising filling the intermediate region of the mold with the mold compound before engaging the mold compound with the microelectronic device.
 5. The method of claim 1, further comprising passing the mold material along a generally straight flow axis through the intermediate region and into the device region of the mold.
 6. The method of claim 1 wherein the entrance port is a first entrance port, further comprising: passing a first portion of the mold material through the first entrance port; passing a second portion of the mold material through a second entrance port; combining the first and second portions of the mold material in the intermediate region to form a combined portion of mold material; and passing the combined portion of mold material through the single opening into the device region of the mold.
 7. The method of claim 1 wherein the entrance port is a first entrance port and the microelectronic device has a forward edge with a forward edge length facing toward the intermediate region, further comprising: passing a first portion of the mold material through the first entrance port; passing a second portion of the mold material through a second entrance port; combining the first and second portions of the mold material in the intermediate region to form a combined portion of mold material having a leading edge approximately parallel to the forward edge of the microelectronic substrate along the entire length of the forward edge; and passing the combined portion of mold material through the single opening into the device region of the mold.
 8. The method of claim 1 wherein the microelectronic device is one of a plurality of microelectronic devices positioned on the substrate and encapsulating includes encapsulating the plurality of microelectronic devices, further comprising separating adjacent encapsulated microelectronic devices and adjacent portions of the substrate from each other.
 9. The method of claim 1, further comprising: curing a first portion of the mold material in the device region; curing a second portion of the mold material in the intermediate region; and separating the second portion of the mold material from the first portion of the mold material and the microelectronic device.
 10. A method for packaging a plurality of microelectronic devices attached to a substrate, comprising: at least partially enclosing the microelectronic devices in a mold with the microelectronic devices in a device region of the mold, the mold having a plurality of entrance ports coupled to a source of mold material, and an intermediate region between the entrance ports and the device region; passing the mold material through the entrance ports over a surface of the substrate into the intermediate region; and passing the mold material from the intermediate region to the device region through a flow restriction between the intermediate region and the device region before engaging a leading edge of the mold material with the microelectronic devices.
 11. The method of claim 10 wherein the microelectronic devices define an array having an array edge facing toward the intermediate region, the array edge having an array edge length, further comprising forming the leading edge of the mold material to be approximately parallel to the array edge over a substantial portion of the array edge length as the leading edge passes through the flow restriction.
 12. The method of claim 10, further comprising passing the mold material through four entrance ports into the intermediate region.
 13. The method of claim 10 wherein the substrate defines a substrate plane, further comprising restricting the passage of the mold material through the flow restriction in a direction transverse to the substrate plane.
 14. The method of claim 10, further comprising filling the intermediate region of the mold with the mold compound before engaging the mold compound with the microelectronic device.
 15. The method of claim 10, further comprising: curing the mold material to form a first portion of the mold material adjacent the entrance ports and a second portion of the mold material downstream of the first portion and adjacent the intermediate region; and forming cracks in the second portion of the mold material by separating the first portion of the mold material from the second portion of the mold material with none of the cracks intersecting the microelectronic devices.
 16. A method for packaging at least one microelectronic device attached to a substrate, comprising: at least partially enclosing the microelectronic device in a mold with the microelectronic device in a device region of the mold and an edge of the microelectronic device facing toward an entrance port of the mold; and encapsulating the microelectronic device by passing a flow of mold material through the entrance port, into the device region and around the microelectronic device with the flow having a leading edge approximately parallel to the edge of the microelectronic device over approximately the entire length of the edge of the microelectronic device.
 17. The method of claim 16, further comprising: passing a first portion of the flow of mold material through a first entrance port upstream of the device region and into an intermediate region between the first entrance port and the device region; passing a second portion of the flow of mold material through a second entrance port upstream of the device region and into the intermediate region; and combining the first and second portions of the flow to form the leading edge of the flow.
 18. The method of claim 16 wherein the microelectronic device is one of a plurality of microelectronic devices defining a device array, the array having a generally straight array edge with an array edge length, further comprising passing the flow of mold material into the device region and around the array of microelectronic devices with the flow having a leading edge approximately parallel to the array edge over a substantial portion of array edge length.
 19. The method of claim 16, further comprising: passing the flow from the entrance port into an intermediate region between the entrance port and the device region; and passing the flow through a flow restriction between the intermediate region and the device region upstream of the microelectronic device.
 20. A method for packaging at least one microelectronic device attached to a substrate, comprising: at least partially enclosing the microelectronic device in a mold with the microelectronic device in a device region of the mold; encapsulating the microelectronic device by passing a flow of mold material through an entrance port of the mold and into an intermediate region of the mold between the entrance port and the device region; and filling the entire intermediate region before passing the flow into the device region of the mold through a flow restriction between the intermediate region and the device region and upstream of the microelectronic device.
 21. The method of claim 20, further comprising: passing portions of the flow through a plurality of entrance ports; and combining the portions in the intermediate region.
 22. The method of claim 20 wherein the microelectronic device is one of a plurality of microelectronic devices defining a device array, the array having a generally straight array edge with an array edge length, further comprising passing the flow of mold material into the device region and around the array of microelectronic devices with the flow having a leading edge approximately parallel to the array edge over a substantial portion of the array edge length.
 23. A method for packaging a microelectronic device attached to a substrate, comprising: at least partially enclosing the microelectronic device in a mold with the microelectronic device in a device region of the mold; encapsulating the microelectronic device by passing a flow of mold material through one or more gates, through a flow restriction downstream of the gates, into the device region and around the microelectronic device with a surface of the microelectronic device nearest to the flow restriction separated from the flow restriction by a distance of at least approximately 4 mm; and separating a first portion of the mold material adjacent the microelectronic device and on a first side of the gate from a second portion of the mold material on a second side of the gate.
 24. The method of claim 23, further comprising: forming cracks in the first portion of the mold material, the cracks defining to form a cracked region with none of the cracks in the cracked region intersecting the microelectronic device; and separating the cracked region of the device portion from a remaining part of the device portion.
 25. The method of claim 23, further comprising: passing the flow through the one or more gates into an intermediate region of the mold between the one or more gates and the device region of the mold; and passing the flow into the device region of the mold through the flow restriction between the intermediate region and the device region and upstream of the microelectronic device.
 26. A method for packaging microelectronic devices attached to a substrate and defining an array having a first edge and a second edge opposite the first edge, comprising contacting the first edge of the array with a mold material having a leading edge generally aligned with the first edge of the array by at least partially enclosing the array in a mold cavity having a first surface with a plurality of gates facing the first edge of the array, and a second surface opposite the first surface, with the first edge of the array spaced apart from the first surface of the cavity by a first distance greater than a second distance between the second edge of the array and the second surface of the mold cavity, and passing a flow of mold material into the cavity through the entrance ports.
 27. The method of claim 26, further comprising: passing the flow of mold material into an intermediate region of the mold between the gates and the first edge of the array, with the first surface of the mold defining a surface of the intermediate region; and passing the flow toward the array through a flow restriction between the intermediate region and the array.
 28. The method of claim 26, further comprising selecting the array to have ten microelectronic devices arranged in two rows with each row having five microelectronic devices.
 29. The method of claim 26, further comprising selecting the array to have twelve microelectronic devices arranged in three rows with each row having four microelectronic devices.
 30. A method for packaging a microelectronic device attached to a substrate, comprising: at least partially enclosing the microelectronic device in a mold with the microelectronic device in a device region of the mold; encapsulating the microelectronic device by passing a flow of mold material into the device region and around the microelectronic device; forming cracks in the mold material to form a cracked portion by removing a residual portion of the mold material spaced apart from the microelectronic device from an adjacent portion of the mold material adjacent to the microelectronic device, with no cracks in the cracked portion extending to the microelectronic device; and separating the cracked portion of the encapsulating portion from the adjacent portion.
 31. The method of claim 30, further comprising: passing the flow of mold material through a plurality of entrance ports into an intermediate region of the mold upstream of the device region; and passing the flow of mold material from the intermediate region to the device region through a flow restriction between the entrance ports and the microelectronic device.
 32. The method of claim 30, further comprising: passing the flow of mold material through a plurality of entrance ports into an intermediate region of the mold upstream of the device region; passing the flow of mold material from the intermediate region to the device region through a flow restriction between the entrance ports and the microelectronic device; and filling the intermediate region of the mold with the mold material before engaging the mold material with the microelectronic device.
 33. The method of claim 30 wherein the entrance port is a first entrance port, further comprising: passing a first portion of the mold material through the first entrance port; passing a second portion of the mold material through a second entrance port; combining the first and second portions of the mold material in the intermediate region to form a combined portion of mold material; and passing the combined portion of mold material through the single opening.
 34. The method of claim 30 wherein the entrance port is a first entrance port and the microelectronic device has a forward edge with a forward edge length facing toward the intermediate region, further comprising: passing a first portion of the mold material through the first entrance port; passing a second portion of the mold material through a second entrance port; combining the first and second portions of the mold material in the intermediate region to form a combined portion of mold material having a leading edge approximately parallel to the forward edge of the microelectronic device along the entire length of the forward edge; and passing the combined portion of mold material through the single opening.
 35. The method of claim 30 wherein the microelectronic device is one of a plurality of microelectronic devices positioned on the substrate and encapsulating includes encapsulating the plurality of microelectronic devices, further comprising separating adjacent encapsulated microelectronic devices from each other.
 36. A method for packaging at least one microelectronic device attached to a substrate, comprising: injecting a mold compound into a mold at least partially enclosing the microelectronic device, the mold compound flowing first through at least one entrance port, then through an intermediate region downstream from the entrance port, and then through a device region downstream from the intermediate region, wherein the microelectronic device is positioned solely in the device region; and restricting the flow of mold compound between the intermediate region and the device region.
 37. The method of claim 36 wherein the substrate defines a substrate plane, further comprising restricting the passage of the mold material through the single opening in a direction transverse to the substrate plane.
 38. The method of claim 36, further comprising filling the intermediate region of the mold with the mold compound before engaging the mold compound with the microelectronic device.
 39. The method of claim 36, further comprising passing the mold material along a generally straight flow axis through the intermediate region and into the device region of the mold.
 40. A microelectronic device package, comprising: a substrate; at least one microelectronic device attached to the substrate; and a hardened mold material at least partially enclosing the microelectronic device, the mold material having a device portion immediately adjacent to the microelectronic device, a gate portion spaced apart from the device portion, and an intermediate portion between the gate portion and the device portion, the mold material having an indentation defining a boundary between the device portion and the intermediate portion with a first cross-sectional area of the mold material at the indentation being less than a second cross-sectional area immediately adjacent to the indentation in the device portion and less than a third cross-sectional area immediately adjacent to the indentation in the intermediate portion.
 41. The package of claim 40 wherein the first, second and third cross-sectional areas are transverse to a flow direction of the mold material toward the microelectronic device.
 42. The package of claim 40 wherein the microelectronic device is one of a plurality of microelectronic devices arranged in an array, further wherein the hardened mold material has a first edge aligned with a first edge of the array and separated from the first edge of the array by a first distance, a second edge aligned with a second edge of the array opposite the first edge of the array and separated from the second edge of the array by a second distance, a third edge aligned with a third edge of the array between the first and second edges of the array and separated from the third edge of the array by a third distance, a fourth edge aligned with a fourth edge of the array and spaced apart from the fourth edge of the array by a fourth distance, the array being asymmetrically positioned in the hardened mold material with the first distance greater than the second distance and the first edge of the mold material defining an outer edge of the intermediate portion of the mold material.
 43. The package of claim 40 wherein the intermediate portion has a widthwise dimension transverse to a flow direction of the mold material toward the microelectronic device, the intermediate portion further having a lengthwise dimension aligned with the flow direction, a ratio of the widthwise dimension to the lengthwise dimension being from about 10 to about
 15. 44. The package of claim 40 wherein the microelectronic device is one of a plurality of microelectronic devices.
 45. The package of claim 40 wherein the microelectronic device is one of ten microelectronic devices arranged in a five by two array.
 46. The package of claim 40 wherein the intermediate portion tapers outwardly with a widthwise dimension of the intermediate portion greater at a point spaced apart from the microelectronic device by a first distance than at a point spaced apart from the microelectronic substrate by a second distance greater than the first distance.
 47. The package of claim 40 wherein the intermediate portion has a first width transverse to a flow direction of the mold material toward the microelectronic device and the device region has a second width transverse to the flow direction, a ratio of the first width to the second width being from about 0.3 to about 1.0
 48. The package of claim 40 wherein the intermediate portion has a first length aligned with a flow direction of the mold material toward the microelectronic device and the device region has a second length transverse to the flow direction, a ratio of the first length to the second length being from about 0.02 to about 0.10.
 49. The package of claim 40 wherein a ratio of a volume of the intermediate portion to a volume of the device portion is from about 0.02 to about 0.07.
 50. A microelectronic device package, comprising: a substrate; a plurality of microelectronic devices attached to the substrate, the microelectronic devices defining an array having a first edge and a second edge opposite the first edge; and a hardened mold material at least partially enclosing the microelectronic devices, the mold material having a first surface aligned with and spaced apart from the first edge of the array by a first distance, the mold material further having a second surface aligned with and spaced apart from the second edge of the array by a second distance greater than the first distance, and the mold material having an indentation between the first and second surfaces.
 51. The package of claim 50, further comprising a gate portion of the mold material spaced apart from the second surface, wherein the second surface of the mold material defines an intermediate portion between the gate portion and the array, the intermediate portion having a widthwise dimension transverse to a flow direction of the mold material toward the array, the intermediate portion further having a lengthwise dimension aligned with the flow direction, a ratio of the widthwise dimension to the lengthwise dimension being from about 10 to about
 15. 52. The package of claim 51 wherein the intermediate portion tapers outwardly with a widthwise dimension of the intermediate portion greater at a point spaced apart from the array by a first distance than at a point spaced apart from the array by a second distance greater than the first distance.
 53. The package of claim 50 wherein the array includes ten microelectronic devices arranged in two rows of five microelectronic devices.
 54. A mold for packaging a plurality of microelectronic devices, Comprising: a mold body having an external surface, an internal surface defining a mold cavity, and an engaging surface configured to engage the substrate, the mold cavity having: a device region configured to extend at least partially around the microelectronic devices; at least one entrance port in fluid communication with the device region and configured to be coupled to a source of mold material; an intermediate region between entrance port and the device region; and a flow restrictor between the intermediate region and the device region, with cross-sectional areas of the mold cavity immediately upstream and downstream of the flow restrictor being larger than a cross-sectional area of the mold cavity at the flow restrictor.
 55. The mold of claim 54 wherein the intermediate region has a widthwise dimension transverse to a flow direction of the mold material toward the device region, the intermediate region further having a lengthwise dimension aligned with the flow direction, a ratio of the widthwise dimension to the lengthwise dimension being from about 10 to
 15. 56. The mold of claim 54 wherein the intermediate region tapers outwardly with a widthwise dimension of the intermediate region greater at a point spaced apart from the device region by a first distance than at a point spaced apart from the device region by a second distance greater than the first distance.
 57. The mold of claim 54 wherein the intermediate region has a first width transverse to a flow direction of the mold material toward the device region and the device region has a second width transverse to the flow direction, a ratio of the first width to the second width being from about 0.3 to about 1.0.
 58. The package of claim 54 wherein the intermediate region has a first length aligned with a flow direction of the mold material toward the device region and the device region has a second length transverse to the flow direction, a ratio of the first length to the second length being from about 0.02 to about 0.10.
 59. The package of claim 54 wherein a ratio of a volume of the intermediate region to a volume of the device region is from about 0.02 to about 0.07. 